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Otomoto Supercar Project part 3

 by otomoto on 14 Oct 2014 |
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Supercar Project Part 3

About this time the guards on the left side got cut to start the replication process. You can see why it's important to use a car you're not very attached to

Having done the other side already it was easier to mould up the left side quickly. The same bits of corflute got cleaned up and re-used.

Having hacked away the majority of the excess foam, a snap-off knife refill blade is used to do some finer scupting, followed by light-pressure sanding with coarse sandpaper.
More foam was added here and there to get the right heights. As you can tell by the jacket, it was a bit cold in the warehouse when this stage was going on.

Here the general shape of the rear bar is pretty much done, but it will extend down under the fuel tank later and have vertical panels in the style of a race diffuser.
Chances are it won't have any useful aerodynamic effect, but hopefully it will look good

Filling up the front took a lot of cardboard. The original panel between the headlights will be used as part of the mould, so the bolts at the back edge can be used to secure the final version.
Note that it will extend over the top corner of the headlight, creating a parallel line with the guard.
The combined LED parker/indicator lights will sit roughly where you see them here, with perspex covers extending forward to change the look of the lights.
The factory bumper support will be kept, with the new panel resting against it, probably with silcone sealant to hold it in place and stop vibration.

The trouble with expanding foam is it gets big air-bubbles in it as it expands. Filling these voids and adding little bits of foam to change the shape adds a lot of time to the process.
About this time passers-by were very confused by what we were doing. Many assumed we were going to drive it around just covered in foam...

This shot was taken at the same time as the one above. There is more foam to be added behind the rear wheel to bring the panel lower and lot of subtle shape changes to come.
Next instalment coming soon!

Text, photos and bodywork by Ben Ellis ©2014 all rights reserved


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